America's largest electrical workshop.

America's
Largest Electrical

Workshop

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AMERICA'S
LARGEST ELECTRICAL

WORKSHOP

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SCHENECTADY WORKS

OF THE
GENERAL ELECTRIC COMPANY

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AMERICA'S LARGEST

ELECTRICAL WORKSHOP

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f I ^HE Schenectady Works of the General Electric Com-
pany stands at the eastern entrance to the Mohawk
Valley. Close by, is the site of the palisaded settle-
ment which, in the year 1661, pointed the westward impulse
of civilization and which has since become a notable city
of over ninety thousand inhabitants. From here, explorers
and settlers have opened long paths to distant lands of
opportunity. Here, with fine symbolism, a noble bridge has
been named The Great Western Gateway; and here the
General Electric Company preserves the pioneer tradition
and spirit by its leadership in the design and manufacture
of electric apparatus — products that are aiding human
progress throughout the Nation and beyond its borders.

At Schenectady, General Electric has established its
principal administrative offices, whence radiate influences
that aid the whole electrical industry in its business of fur-
thering scientific, commercial, and cultural advance. Most
of these offices are in Building 2, which fronts the main gate
and is one of the largest office buildings in America used ex-
clusively by one company.

In addition to departments which are charged with admin-
istration of General Electric's affairs or are occupied with
various forms of general service to its organization, most
of the principal sales departments of the Company are also
at Schenectady. Here engineering knowledge is combined
with commercial experience to extend the market for G-E
products and to serve purchasers in matters of installation
and operation.

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THE Schenectady Works Is the largest electrical manu-
facturing plant in America. Turning from Building 2, one
faces the long vista of "Works Avenue," lined on both sides
with factories and crowned by the lofty towers of WGY,
one (jf the country's oldest radio broadcasting stations. This
avenue and its intersecting streets may well be likened to
those of a modern city. On an area of 645 acres and with a
total floor space of over six and a half million square feet,
353 buildings house a daily population of from 18,000 to
20,000 men and women, not Including the 2000 who occupv
the general offices. Manufacturing activities are conducted
from Building 41, situated at a central and convenient loca-
tion with respect to the shops. The executives are assisted
by a Works Council elected by the employees. Safety and
order are promoted by a fire department equipped with
modern apparatus and by a patrol department of 90
members.

Within the plant are 23 niHes of track on which 22 elec-
tric locomotives and 800 freight cars are operated, while
a ficet of 160 automobiles and trucks also plays an important
part in the traffic. Beneath the pavements is an elaborate
system of pipes and conduits which serves the commimity*s
needs for heat, light, water, and power. The pumping sys-
tem has a daily capacity of 2^^,000,000 gallons, exclusive of
the drinking-water system, and the radiators and pipe coils
are sufficient to heat more than 2700 homes of average size.
Communication is made easy by an autonuitic telephone
system which includes more than 3500 instruments. The
Schenectady Works has its own athletic fields and surgical
dispensaries; its restaurants served, in 1927, a total of
1,451,548, meals; and a commodious parking area is pro-
vided for employees* automobiles.

It would take too long a time to study all the shops of the
Schenectady Works; we must be content with a brief visit
to a few typical factories. From these we may estimate
methods of manufacture and the nature of the products.

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These products include:

Large steam turbine-generator

sets
Synchronous converters
Synchronous condensers
Frequency-changer sets
Large waterwheel generators
Motor-generator sets
D-c. motors and generators
A-c. motors and generators

Motors and generators for
ship propulsion

Mercury-arc rectifiers

Elevator motors and control

Motor- and generator-
control apparatus

Voltage regulators

Searchlights

Marine generator sets

Wire and cable

Induction motors

and generators for Refrigerators
steam-railroad electrification Radio apparatus

Motors

While it is not always safe to measure excellence in terms
of size, we must consider that the electrical service supplied
by most of these products widens in scope in proportion to
the capacity — and hence to the dimensions — of the appa-
ratus. This greater size, in turn, requires heavier and larger
manufacturing machinery. Therefore, the unusual magni-
tude of apparatus and of operation in the General Electric
shops demands notice in even a brief description.

These characteristics, together with finished craftsman-
ship guided by expert design, are so general and distinctive
a feature of manufacture at the Schenectady Works that a
few shops, selected for diversity of product, will fairly repre-
sent the whole.

More than 15 years of research and development are
behind the activities in Building 23. Several thousand re-
frigerators of 19 difl'^erent types were field-tested and im-
proved before the present models were standardized. In all,
upwards of 300,000 square feet of floor space and the services
of I400 skilled workers are devoted to the production of elec-
tric refrigerators at a rate faster than one every minute.
Every part is carefully Inspected; and at many stages of
assembling, thorough tests are conducted. Every refrigerator
unit, as it leaves the loading platform of Building 23, carries
with it the evidence of trained hands, coordinated efl^ort, and
rigid standards of manufacture.

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Notable among these shops is Building i6, where water-
wheel-driven turbines and large motors are made. Here is a
65-foot boring mill — one of the largest of its kind in the world.
Ot' the 23^,784 square feet of area in this shop, an iron
floor occupies 14,500. On account of the huge size of the
castings that must be handled, they are set up and machined
with electrically driven tools on this flooring, which thus
virtually constitutes a vast bench at which the giant
Electricity performs his mighty and nicely accurate labor.

Building 17 presents another aspect of Schenectady Works
production. Here 6,000,000 pounds of sheet steel are con-
sumed each month. Speed — sheer, bewildering speed — com-
pels attention to the punch presses, some of which pour out
metal parts at the rate of 700 every minute. The total
capacity of this department is a million and a half stampings
per hour. The weight of the smallest punching is .00001224
of a pound; the largest weighs 880 pounds. Tn the same build-
ing are is electric welding machines that make an average
total of 600,000 welds a day.

Building 49 houses some of the largest lathes ever built.
These are required to machine the ponderous rotor forgings
for large steam turbine-generators.

Although the machinery and products of these shops
have given the visitor opportunity to adjust his apprecia-
tion to an extraordinary scale of manufacture with its sug-
gestion of corresponding electrical capacity, he can hardly
be prepared for the majestic dimensions and far-reachin
vistas of Building 60, the largest shop in the Schenectady
Works. It is 800 feet long and 340 feet wide, with a floor
area of more than half a million square feet, including the gal-
leries. Its construction demanded about 8400 tons of steel,
4,000,000 bricks, 100 miles of wire, 10 miles of steam pipe,
and 154,000 square feet of window and skylight glass.

Building 60 is, in large part, devoted to the making and
assembly of steam turbine-generators of the largest capaci-
ties — machines of such dimensions as are indicated by
illustrations in this book. To move the great machinery
parts from point to point, 44 overhead electric cranes are

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required, several of which have a hfting power of loo tons
each. The shop is equipped also with 900 motor-driven
tools operated by 1500 motors, which furnish a total of
about 13,000 horsepower. There are few great factory
buildings in which electric power so conspicuously serves
the minds that direct it; there is, perhaps, no other in
which has been fabricated machinery with a capacity for
so large a production and so wide a distribution of electric
energy.

In Building 68, the ancient art of the potter is applied to
the requirements of electrical manufacture through modern
machinery capable of large-quantity production. The 80
presses and the kilns in this porcelain factory daily convert
16 tons of raw material into about 275,000 pieces of porce-
lain.

It may seem a long step from porcelain to wire, but in
the manufacture of these products at the Schenectady Works
there is the same careful direction of process, the same
reliance on modern machinery, and the same provision for
production in large volume.

In Buildings 85 and 109, three billion feet of insulated
wire and 31 billion feet of uninsulated wire — having a total
weight, in copper alone, of 25,000,000 pounds — are manufac-
tured yearly. Building 85 contains two parallel units which
can be used simultaneously or separately. The raw material
is received at one end of the structure, and the finished
product is loaded on cars at the opposite end at a rate of
about 1,000,000 pounds of finished cable per week.

Building 77, situated almost at the southern end of
**Works Avenue," is dedicated to the youngest and most
humanly intimate branch of the electrical art. Here is made
radio apparatus for both transmission and reception. The
products of this factory embody the latest inventions and
refinements of the Company's radio engineers, and, through
their ever-increasing excellence, are bringing pleasure and
benefit to homes in every part of the continent. General
Electric has contributed three broadcasting stations to the
service of this art — WGY, at Schenectady; KOA, at Denver;

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and KGO, at Oakland. The towers of WGY, on the roof of
Building 40, rise to a height of 265 feet from the ground
and are 352 feet apart. The studio and engineering staffs
of this station number 23 persons, who, in their several
capacities, supervise the broadcasting of programs origi-
nating at Schenectady and of material received by wire
from prominent musical centers.

To one who has visited these representative buildings
of the Schenectady Works, the question is likely to occur:
*'How does General Electric 'make delivery'?'* Statistics
of the Shipping Department show that it occupies, in all,
eight or nine acres, that it uses 14,500,000 board feet of lum-
ber a year, 170,000 pounds of banding iron, 216,000 pounds of
wrapping paper, and — each day — a ton and a half of nails.
The Department receives about 160,000 orders and loads
nearly 13,000 cars annually. About 230,000 memoranda of
shipments are sorted and mailed each year. Containers to
the number of 1,800,000 are used annually to ship products
having a total tonnage of 170,000. Shipping faciliries
throughout the Works enable the loading of 107 cars at one
time.

The Research Laboratory, occupying Buildings 5 and 37, is
not only the scientific fountainhead of the whole Company in
all matters pertaining to research and development; it is an
institution of international authority and importance. Its
large staff of technical investigators, recruited from almost
every department of physical science, is not only engaged in
the study of electrical phenomena and materials; it also
makes valuable contributions to branches of knowledge
that have, perhaps, only an indirect relation to electrical
development but are of the first importance in other
industrial fields and in the sphere of pure science. In this
laboratory, through brilliant theory and patient experiment,
the incandescent lamp was brought from its early form to
its present high effectiveness and general availability. Here
also, x-ray apparatus, essential in modern medical diagnosis,
and power tubes, important in many technical applications,
have been developed. The millions of dollars invested by

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General Electric in the equipment and maintenance of the
Research Laboratory have returned rich dividends in the
form of scientific understanding and humanitarian service.

Building 37, adjacent to Building 5 and conspicuous
because of the great electric sign on its roof, is devoted prin-
cipally to the manufacture of laboratory products.

The scientific equipment at the Schenectady Works also
includes laboratories for general engineering and for the
testing of materials, as well as an Illuminating Engineering
Laboratory situated outside the Works proper, where the
spectacular floodlighting of the Panama-Pacific Exposition
and that of Niagara Falls were planned.

The Works management welcomes visitors who are inter-
ested in scientific and industrial development. The service of
guides is available at stated hours each day and covers the
points of principal interest described in the foregoing pages.
Special arrangements are made for the reception of conven-
tions, technical societies, and student bodies, and it is the
object of the management to render these visits informative
and pleasant.

The General Electric Company has established an edu-
cational as well as a scientific and an industrial center at
Schenectady. In the development of a curriculum, the Com-

panyhas been prompted by a sense of moral obligation to give
its employees suitable help in improving their understandin
and also by a prudent concern for the future of the electrical
industry itself. On the one hand, it seeks to supply those
elements of knowledge which may be missing in the Hves of
competent employees; on the other, it recognizes the impor-
tance of sending out young men completely equipped to serve
the large purposes of the industry in other fields.

For foreign-born employees who desire to qualify them-
selves for American citizenship, a free course of instruction
is conducted by teachers recruited from the G-E organiza-
tion. The subjects include, so far as is necessary, all those
taught in elementary schools, with special attention to read-
ing and writing English.

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For hoys and young men who possess mechanical ahility
and who have not gone beyond grade or high school, a four-
year course ot paid educational employment offers a valu-
able foundation for the trade career in which they respec-
tively develop the greatest aptitudes. At the same time, they
attend graded classes in mathematics, mechanical drawing,
and such other subjects as will add to their mental and tech-
nical equipment and will further their advancement either
with this company or elsewhere.

Evening vocational courses are available in bliop arith-
metic, F-nglisli, typcwTiting, stenograph), engineering
mathematics, machine design, blueprint reading, mechanical
drawing, electrical engineering theory, shop practice, and
cognate subjects. These courses, offered to employees who
tlesire to improve their qualificiirions for advancement,
maybe supplemented f)y intensive instructions in commercial
and administrative work, accounting, auditing, and com-
mercial law, anil by special training in technical sales pro-
motion.

A I^'actory Training Course is conducted for a limited
num!)er of engineering graduates who are intere-..^d in work
of an executive nature in the manufacturing organization.
'Jhe students obtain experience in the factory by a ■ -ignments
to several departments doing work on all types of machine
tools and also by working in the foundry and pattern shop.
They become huiiillar with shop office practice by assign-
ments to production, piece rate, and cost departments.
They are also given special work in the Business Training
Course for the purpose of obtaining experience In business
organization and accounting.

The Student Fngineering Course, open to college gradu-
ates in engineering, supplements theoretical instruction
with study and practical experience in design, manufacture,
construction, and research in the shops. Its object is to train
young engineers for positions in the designing, commercial,
and executive departments, and for service with public
utility companies. It is often referred to as the "Test
Course'*, and the student engineers are popularly called

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EDISOX CLUB HA LI

The many social and educational activities of the Edison Club

are conducted in this building

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Ui_.^£RAL ELECTRIC »> 0\f AV S CLUB

In this club Iiome, women employee.^ find congenial company

and form L.,:*.ng fricndshl|>s

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"Test Men". The apparatus is delivered for testing as
assembled units. The students wire^ start, and adjust these
units, making sure that they meet specifications and are in
proper condition before they are finally approved and shipped.
The average time of training is from 12 to 15 months, and
the number admitted to the course varies from 300 to 500
annually. Approximately 135 colleges and 25 nations have
been represented in this student body.

To a limited number of highly qualified men, General
Electric offers a three-year advanced course in design engi-
neering, the last two years of which are spent in the Com-
pany's engineering offices, where actual day-by-day prob-
lems are solved. Here the opportunity to develop leadership
in technical fields is very favorable for men of distinctive
ability.

A sales course is conducted for those who desire to enter
the sales engineering field, and a course in accounting,
administration, and like subjects is available for graduates
of non-technical colleges. Those who wish to earn post-grad-
uate degrees in engineering may take up the necessary work
at Union College, Schenectady, while employed by the Com-
pany. Several undergraduate scholarships at Union College
have been established by General Electric for young men
in its employ and for sons of employees.

It is as important to encourage men and women in the
practice of thrift as to help them increase theirearning power.
The General Electric Company offers to the members of
its organization advantageous investments and provision
for a possible time of trouble. It has organized the G.F.
Employees Securities Corporation, the funds of which are
invested in General Electric securities and in those of elec-
trical public utilities. The bonds of this corporation are sold
to G-E employees, w^ho may buy them either for cash or by
weekly or monthly deductions from pay.These bonds return
six per cent interest, to which General Electric adds two per
cent so long as the holder remains in its employ. These
issues, redeemable at any time, have been subscribed to
an amount of over ^36,000,000 by more than 30,000
employees.

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Recognizing the value of continuity of service, the Com-
pany gives supplementary compensation to those who have
been in its employ for five years and who receive less than
I4000 a year. This compensation (five per cent of the
employees* annual pay) amounted in 1927 to more than
J 2,900,000.

There are 19,000 employees at the Schenectady Works
who are covered for ^23,000,000 of group life insurance, the
premiums being paid by the Company. Employees also
subscribe to additional insurance of a larger amount,
for which they pay by payroll deduction at low premium
rate. During 1927, total claims paid to families of Schenec-
tady employees were over $260,000.

A Relief and Loan Plan maintained for employees at
Schenectady makes loans to its members who may be in
need of funds on account of temporary unemployment,
illness, or other emergency. The fund is provided by monthly
payments by members, with an equal amount contributed
by the Company. During the last year, loans to employees
have reached nearly $75,000.

The Company welcomes suggestions from its employees
toward improvements in manufacture or design of apparatus
or changes tending to increase the safety of working con-
ditions. i\ll suggestions are carefully considered, and merited
awards are paid to the employees.

A Mutual Benefit x-^ssociation, conducted by employees,
has paid sickness and death benefits for the last several
years. Recently there has been added a hospitalization
benefit feature. Membership fees and dues are collected by
the Company by payroll deduction, and all employees
under 55 years of age are eligible to join the Association.
More than 1 1,000,000 has been paid to employees durin
the last 15 years.

The Company has maintained for many years a Pension
System for retiring employees after they have reached the
age of 70 years with a continuous service of 20 years or more.
Recently a provision was added to the Pension Plan whereby
employees may contribute a portion of their annual earn^

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ings to a fund maintained by the Company. Under the new
plan, the employee may retire at the age of 65 years; he
then receives his accumulated funds in addition to the usual
pension payment.

A Works Council has been organized at Schenectady for
the consideration of problems pertaining to the employees
and their relationships with the management. It is com-
posed of elected representatives of the employees, the Works
Manager, and other Works executives. Regular meetings
are held to discuss and solve questions and make recom-
mendations concerning Works policies and conditions
affecting all employees.

A General Safety Committee composed of representatives
from every department in the factory is organized to pro-
mote "safety first" throughout the Works. It supervises
accident-prevention campaigns and assists materially in
the reduction of lost-time accidents and serious injuries to
employees.

A fully equipped hospital with a large staff of physicians
and nurses is maintained. Emergency service and subsequent
treatment are afforded all injured employees. First-aid
service is rendered in the case of illness, after which the
employee is referred to his family physician. X-ray service is
available to all employees for purposes of diagnosis. The
hospital staff maintains a high standard of sanitation
throughout the factory and furnishes rest rooms wherever
women are employed.

Social and recreational advantages are provided for those
in the service of the Company. Prominent among these is
the Edison Club, which furnishes modern club facilities to
members of the Testing Department and to the younger engi-
neers. Its equipment includes a club house with reading and
billiard rooms, a large hall for lectures, dances, and dinners,
bowling alleys, and a boat house. A country club also has
been organized for the benefit of student engineers. Its club
house and golf links are on the bank of the Mohawk River,
a few miles from Schenectady.

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THE TOWERS OF WGY

The broadcasting towers of WGY are on the roof of Building 40

The Company also maintains a large developmental

station at South Schenectady

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The General Electric Woman's Clubj organized for the
promotion of acquaintance and mutual helpfulness among
women employees of the Company, has its home a short
distance from the Works. Here athletic classes are conducted
and social events are held. Lunch is served daily at a small
charge. A well-appointed summer camp on Lake George has
been established for the women and girls of the G-E organi-
zation. Carefully supervised and with every facility for out-
door enjoyment, it offers an ideal vacation place at a cost
that barely covers expenses.

An athletic field, with baseball diamonds, tennis courts,
and track facilities, is maintained by the Company for the
encouragement of individual development and for group
sports.

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The Schenectady Works of the General Electric Company
was established in 1886, when the Edison Machine Works
(afterwards part of the Edison General Electric Company)
acquired two buildings (now known as 10 and 12) on the
site of the present plant and began operations with
about 300 employees. In 1892, the Edison General Electric
Company and the Thomson-Houston Electric Company, of
Lynn, Mass., were merged under the name, General Electric
Company. In addition to the plants at Schenectady and
West Lynn, there are now large factories at Pittsfield, Mass.;
Erie, Pa.; Ft. Wayne, Ind.; Bridgeport, Conn.; Philadelphia,
Pa.; Baltimore, Md.; Harrison, N. J.; and Cleveland, Ohio;
besides smaller factories in other cities. In all, there are 15
plants, having an aggregate floor space of 26,500,000 square
feet and employing more than 70,600 men and women.
Each of these plants speciaHzes in particular lines of prod-
ucts, while some of them, as in the case of lamp factories,
are restricted to one.

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MALlliNIN(, IHfc. VIATOR i-KA.MP OF A 65,000- K f I.O VV A i i

WATLRWHLLL-URIv ^N GENERATOR

This IS tJic lur^^^i generator of its kii.u ev,.f built

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AN ELECTRIC FURNACE USED FOR MELTING

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A CONTRAST IN ARMATURES

The small armature is of the kind built for a i /jo-hp. motor and

weighs less than a pound; the large one, built in Building 15,

weighs 96,000 lb, and is for a 4500-hp. steel-niill motor

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MASS PRODUCTION' OF MOTORS, BUILDING 4O

Practically the whole of this large, five-story building Is devoted
to the different processes necessary to build induction

motors in large quantities

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TURBINE DEPARTMENT, BUILDING 49

Steam tnrhine-generators are assembled and tested in this building

TESTING-FLOOR FOR STEAM TURBINE-GENERATORS,

BUILDING 49

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A I2jOOO-POUND TRIP HAMMER/^BUILDING 94

This shop is entirely devoted to forging-hammers, ranging
from 250-pound electric motor-driven, drop-board

hammers to the giant in the picture

40

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ONE OF THE PORCELAIN-FIRING KILNS^ BUILDING 68

The porcelain products made in this building range in size from
the giant insulators 6 to 8 feet high shown in this picture

to tiny switch parts measured in fractions of an incl

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A 10,000-POUND HYDRAULIC PRESS FOR SHEATHING

CABLES WITH LEAD, BUILDING 85

ONE OF THE CABLE-WRAPPING MACHINES,

BUILDING 85

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Many different kinds of glassware, such as x-ray tuhc^, mercury
rectifier tubes, and all varieties of tubes for experimental

work, are blown in this shop

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December, 1928 (16 M)

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December. 1928 (16M)

[BLANK PAGE]

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